Compounder installation

ABSTRACT

The invention relates to a compounder comprising a mixing unit, which can be mechanically driven by a drive module and is provided with one or more feed devices ( 5 ) for the material to be processed and one or more additives that are to be mixed with this material. The mixing unit is located in a supporting frame configured as a three-dimensional framework, and the supply and discharge lines required to operate the mixing unit, for the material being processed, and auxiliary materials or operational materials and energy as well as for the measurement, control and regulation technologies are substantially completely installed in or on the supporting frame and are connected to the mixing unit. The supporting frame is configured both as a transport frame for transporting the compounder to the job site and as a mounting frame for the placement of the operational compounder on a substructure at the job site. According to the invention, mechanical vibrations caused by the drive module of the mixing unit are kept at bay from the vibration-sensitive devices of the installation.

DESCRIPTION

[0001] The invention relates to a compounder according to the preambleof claim 1.

[0002] Compounders for mixing, for example plastics with additives suchas fiber materials and other additives and colorants, to produce agenerally granulated compounded material to be used for furtherprocessing normally include a screw extruder as central part for mixingvarious materials to be processed. The mixing units typically involvedhere are twin screw extruders rotating in same direction or oppositedirection and operated by a drive module which normally includes anelectric motor and an attached gearbox. Of course, it is also possibleto provide a different drive, for example a hydraulic motor. Heretofore,such a mixing unit is typically equipped with a separate machine framefor support of the drive module and the processing unit (extruder barrelwith the extrusion space). Up to now, it has been common practice toseparately transport the mixing unit and the supply and discharge lines,required for operation of the mixing unit, for material being processedand auxiliary and process materials and energy as well as formeasurement, control and regulation technologies as well as the requiredswitch cabinets and auxiliary devices (e.g. weigh feeders, suctionunits), and to position and operatively connect them at the job site.This significantly complicates the assembly and the break-in of thecompounder by the personnel of the plant manufacturer at the job site.

[0003] In order to reduce the assembly works and facilitate the break-inoperation, it has been known to complete installation of at least theessential parts of the compounder, i.e. in particular the actual mixingunit with the periphery required for operation, in a three-dimensionalframework already at the manufacturing factory and to transport thispractically operational construction together with the three-dimensionalframework to the job site, where it is only necessary to place thethree-dimensional framework upon the prepared substructure and to anchorit. There is no need to lay and mount the supply and discharge lines foroperation of the compounder at the job site, so that the time tocommence operation is reduced to a small fraction of the otherwisetypical time. Thus, the three-dimensional framework assumes hereby notonly an essential function for the transport of the compounder butremains at the job site also a part of the overall plant so as to assumealso the function of a mounting frame that is only required to be placedupon a substructure.

[0004] The mounting of the lines and individual units at the factory endin or on the three-dimensional framework is accompanied, however, alsoby a significant drawback because vibrations, caused in particular bythe drive module of the mixing unit, are transmitted via the supportingframe also onto other units which are sensitive to vibrations. Anexample includes the weigh feeders whose precision is adversely affectedby mechanical vibrations. Such vibrations may also damage electronicdevices and lead, for example, to malfunction of plugged boards as aresult of a loosening.

[0005] Remedies, involving an indirect connection of the mixing unitwith its drive module to the three-dimensional framework throughintervention of dampening elements (e.g. rubber pads), resulted in asignificant but still in many cases insufficient improvement.

[0006] It is an object of the present invention to improve a compounderaccording to the preamble of claim 1 in such a way that mechanicalvibrations caused by the drive module of the mixing unit are preventedfrom adversely affecting the operation of the compounder in a simplestpossible manner.

[0007] This object is attained in accordance with the present inventionby an apparatus having the features set forth in claim 1. The sub-claimsrecite advantageous improvements of the invention.

[0008] The solution according to the invention is based on the principleto provide a substantially complete decoupling between drive module andthe supporting frame, designed as three-dimensional framework, for thecompounder, whereby the functionality of the supporting frame remainsfully intact for the transport from the manufacturer's factory to thejob site. This means that the mixing unit is fixedly connected with thesupporting frame during transport. The connection is implemented bydetachable connections which are removed again at the job site. Theessence of the invention is the securement of the drive module, which inmost cases is comprised of an electric motor and a coupled gearbox, upona common intermediate frame for both units. It is also possible,although less advantageous, to provide separate intermediate frames forboth units. The intermediate frame can be effectively lifted from thesupporting frame by means of supports, which can be placed at the jobsite upon the substructure underneath the intermediate frame throughopenings in the bottom of the supporting frame, or are already mountedto the intermediate frame. The intermediate frame rests thus only duringtransport directly on the supporting frame and is fixed thereto. At thejob site, the intermediate frame is slightly lifted from the bottom ofthe supporting frame, after detaching the fixation, when the supportingframe is placed upon the substructure. It is hereby essential that thedrive module, despite this elevation, virtually retains the readyposition which has been maintained also during the transport process.Thus, all connections, which have been established during assembly atthe manufacturer's end, remain virtually unchanged during transport andafter the final installation at the job site. The height of the supportsis so dimensioned that lifting of the intermediate frame from thesupporting frame is suitably in the range of, for example, fewmillimeters. It is only required to prevent a direct physical contactbetween the intermediate frame and the supporting frame.

[0009] Suitably, the provision of a separate machine frame for themixing unit, which preferably is a separate twin screw extruder rotatingin same direction or opposite direction, is omitted in the compounderaccording to the invention. This is easily possible because theprocessing unit of the mixing unit, i.e. the extruder barrel, can besecurely connected directly with the drive module, which in turn can befixed via the intermediate frame. The processing unit can hereby besuspended freely, when the length is short enough. In case of a longprocessing unit, the provision of an additional support is recommended.Such a support could be realized on the supporting frame as this wouldbe provided anyway for the transport process. Through intervention ofrespective vibration dampers, the introduction of vibrations via theprocessing unit can be attenuated. Clearly preferred is however asolution in which at least one additional support is provided for theprocessing unit and extended through an opening in the bottom of thesupporting frame, which rests upon the substructure, for direct supportupon the substructure.

[0010] To compensate for manufacturing tolerances of the contact pointsof the substructure for the supports, it may be advantageous toconfigure the supports for carrying the intermediate frame and/orcarrying the processing unit in a height-adjustable manner. Hereby, thesupports may be provided with screw feet which can be secured in thefinal mounting position.

[0011] Suitably, the supporting frame is equipped with a compartmentwhich is enclosed by walls and separated from the part of the supportingframe which houses the mixing unit. This enclosed compartment preferablyaccommodates the necessary switch cabinets for the measurement, controland regulation technologies as well as energy supply. Control may berealized by a typical PC system which can also be accommodated in thisenclosed compartment and thereby remains unaffected from mechanicalvibrations. This compartment may also be kept free from otherinterfering influences such as moisture and high temperature in a simplemanner through air-conditioning.

[0012] Preferably, the supporting frame has a substantially block-shapedconfiguration and has outer dimensions and connection dimensions andconnection devices of a standard container. This is highly advantageouswith respect to handling during road transport or rail transport.

[0013] Suitably, the roof of the supporting frame is configured for foottraffic and provided with fastening devices for mounting additionaldevices for the compounder. Then, the attachment of, for example, aweigh feeder or a further supporting frame with the required meteringdevices can easily be mounted to the roof of the supporting frame. Thenecessary line connections for a weigh feeder are already mounted insidethe supporting frame in the form of prepared interfaces. Of course,during transport, the weigh feeder is dismantled to prevent damage.

[0014] An exemplified embodiment of the invention will now be describedin more detail with reference to the single FIGURE which illustrates aschematic side view of a compounder according to the invention.

[0015] The depicted compounder includes a mixing unit 1, for example atwin screw extruder. The drive module 2 of this mixing unit 1 includesan electric motor 3 and a gearbox 4 coupled thereto. The motor 3 and thegearbox 4 are securely mounted to a common intermediate frame 13.Flange-mounted directly to the gearbox 4 is the processing unit of theextruder in the form of the extruder barrel 6. The extruder barrel 6 isprovided with a funnel-shaped feed device 5 for the materials to beprocessed. The mixing unit 1 is located within a supporting frame 7which is configured as three-dimensional framework and divided in apartial compartment 18 for the mixing unit 1 and a partial compartment19. The supporting frame 7 has a substantially block-shapedconfiguration and has outer dimensions and connection dimensions andconnection devices of a standard container. The bottom of the supportingframe 7 is designated by reference numeral 17. Disposed underneath thebottom 17 are contact points 14 for placement of the supporting frame 7in the final mounting position upon a not shown substructure at therespective job site. Schematically indicated in the compartment 19 aretwo switch or control cabinets 11, 12 to ensure the necessary energysupply (primarily electric current) and the fluid supply (e.g. coolant)as well as the measuring, control and regulation technologies of theplant, for operation of the mixing unit 1. The line extending from theswitch cabinet 11 to the electric motor 3 is designated with 10, whilethe line extending from the switch cabinet 12 to the processing unit 6of the mixing unit 1 is designated with 9. Both lines are shown inbroken line. Placed upon the roof of the supporting frame 7, which isconstructed for foot traffic and subsequently provided with a railing21, is a weigh feeder 20 which is sensitive to mechanical vibrations andhas the task to introduce additives for mixture with the material beingused in the mixing unit 1, via the feed device 5 through a supply line 8into the extruder barrel 6. The weigh feeder 20 is also run by theelectronics installed in the switch cabinet 12. The partial compartment19 is provided in a manner not shown in detail with outer walls andthereby separated from the immediate surroundings and preferablyair-conditioned so that the devices accommodated therein are not exposedto interfering external influences. This is also true for the impact ofmechanical vibrations as caused by the drive module 2 of the mixing unit1. Transmission of these mechanical vibrations onto the supporting frame7 is prevented by lifting the intermediate frame 13, which restssecurely during transport upon the bottom 17 of the supporting frame 7,from the bottom 17 in the illustrated installation position at the jobsite. This is implemented by means of both illustrated supports 15 whichare guided through openings in the bottom 17 and supported directly uponthe not shown substructure. The height of the supports 15 is hereby sodimensioned that the underside of the intermediate frame 13 is liftedfrom the top side of the bottom 17 by a small distance X, shownexaggerated in the illustration and in reality is preferable in therange of millimeters. In the final mounting position, the intermediateframe 13 is thus not supported by the supporting frame 7 but is directlyconnected via the supports 15 with the substructure. In view of itsrelatively great length, the processing unit 6 of the mixing unit 1 isalso supported directly on the not shown substructure by a support 16which extends through an opening in the bottom 17 of the supportingframe 7. During the transport, the processing unit 6 is held by a notshown retention device supported interiorly of the supporting frame 7and removed again at the job site of the plant. The position of themixing unit 1 is virtually the same during transport and after placementof the plant at the job site within the supporting frame. Onlyimplemented is the slight vertical shift by the indicated distance Xafter the final disposition for the operation has been reached. Thisshift is small enough to maintain all connected lines at the mixing unitfor fluid conduction or transmission of signals or electric energy.

[0016] This enables to fully test and break-in the complete plantalready at the manufacturer's end and subsequently to transport italmost unchanged to the job site and to operate it again there, withoutany need for a complicated new break-in procedure. During transport, allunits are sufficiently secured hereby. Yet, when being positioned at thejob site, the particular support of the intermediate frame 13 upon thesupports 15 ensures a complete decoupling from mechanical vibrations.The supports 15, 16 may, optionally, be attached at the job site. Ofcourse, it is also possible to connect the supports already at themanufacturer's end securely with the intermediate frame 13 and theprocessing unit 16, respectively. Hereby, there is no need to extend theunderside of the supports 15, 16 up to beneath the connecting line ofthe contact points 14 on the bottom side of the bottom 17 of thesupporting frame 7. The required height may, for example, be ensured, bythe afore-mentioned height adjustment of the supports 15, 16 or alsothrough a respective elevation on the provided contact points of thesubstructure.

[0017] List of Reference Characters

[0018]1 mixing unit

[0019]2 drive module

[0020]3 motor

[0021]4 gearbox

[0022]5 feed device

[0023]6 extruder barrel (processing unit)

[0024]7 supporting frame

[0025]8 supply line

[0026]9 line

[0027]10 line

[0028]11 switch cabinet

[0029]12 switch cabinet

[0030]13 intermediate frame

[0031]14 contact points

[0032]15 support

[0033]16 support

[0034]17 bottom

[0035]18 partial compartment

[0036]19 partial compartment

[0037]20 weigh feeder

[0038]21 railing

[0039] X small distance

1. Compounder, comprising a mixing unit (1) which can be mechanicallydriven by a drive module (2) and is provided with one or more feeddevices (5) for the material to be processed and one or more additivesto be mixed with this material, wherein the mixing unit (1) is disposedin a supporting frame (7) configured as a three-dimensional framework,and wherein the supply and discharge lines (8, 9, 10), required foroperating the mixing unit (1), for material to be used and auxiliary orprocess materials and energy as well as for measurement, control andregulation technologies are substantially completely installed in or onthe supporting frame (7) and are connected to the mixing unit (1),wherein the supporting frame (7) is configured as a transport frame forthe transport of the compounder to the job site as well as a mountingframe for the installation for operation of the compounder upon asubstructure at the job site, characterized in that the drive module (2)is supported on at least one intermediate frame (13) which can besecured in a position ready for operation in the supporting frame (7) bymeans of detachable connections for the transport, and that there areprovided underneath the at least one intermediate frame (13) supports(15) which extend through openings in the bottom (17) of the supportingframe (7) for support at the job site upon the substructure and sodimensioned in height that the intermediate frame (13) is slightlylifted from the bottom (17) of the supporting frame (7), when thesupporting frame (7) is placed upon the substructure.
 2. Compounderaccording to claim 1, characterized in that the mixing unit (1) isconfigured as screw extruder, in particular as twin screw extruderrotatable in same direction or opposite direction.
 3. Compounderaccording to one of the claims 1 to 2, characterized in that the drivemodule (2) includes an electric motor (2) and a gearbox (4) coupledthereto, with both mounted on a common intermediate frame (13). 4.Compounder according to one of the claims 1 to 3, characterized in thatthe mixing unit (1) is fixedly connected directly with the drive module(2), without separate machine frame.
 5. Compounder according to one ofthe claims 2 and 4, characterized in that at least one additionalsupport (16) is provided for the extruder barrel (6) of the mixing unit(1) and extends through an opening in the bottom (17) of the supportingframe (7) for direct support upon the substructure, when the supportingframe (7) rests upon the substructure.
 6. Compounder according to one ofthe claims 1 to 5, characterized in that the supports (15, 16) areconfigured for height adjustment, in particular configured with screwfeet.
 7. Compounder according to one of the claims 1 to 6, characterizedin that there is provided for control of the compounder a PC systemwhich is disposed inside the supporting frame (7).
 8. Compounderaccording to one of the claims 1 to 7, characterized in that thesupporting frame (7) has a substantially block-shaped configuration. 9.Compounder according to claim 8, characterized in that the supportingframe (7) has outer dimensions and connection dimensions and connectiondevices of a standard container.
 10. Compounder according to one of theclaims 1 to 9, characterized in that the supporting frame (7) has acompartment (19) which is enclosed by walls for accommodation of theswitch cabinets (11, 12) for the measurement, control and regulationtechnologies as well as for the energy supply.
 11. Compounder accordingto one of the claims 1 to 10, characterized in that the roof of thesupporting frame (7) is constructed for foot traffic.
 12. Compounderaccording to one of the claims 1 to 11, characterized in that fasteningdevices are disposed on the roof of the supporting frame (7) formounting of auxiliary devices (weigh feeder 20).